Kawasaki KX85-KX100 2013 Owner's manual
Quick Reference Guide
GENERAL INFORMATION j
This Quick Reference Guide will assist you in
finding the in
A Table of Contents is included after the
Foreword.
formation you’re looking for.
MAINTENANCE AND ADJUSTMENT j
TROUBLESHOOTING GUIDE j
TUNING j
STORAGE j
IMPORTANT INFORMATION
This vehicle is designed for the operator only, no passengers.
•
This vehicle is a competition model only and was not manufactured for use on public streets, roads or
•
highways.
The use of this vehicle should be limited to participation in sanctioned competition events upon a closed
•
course.
This vehicle should not be used for general off-road recreational riding.
•
Read owner’s manual.
•
Whenever you see the symbols shown below,
heed their instructions! Always follow safe operating and maintenance
practices.
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in de ath
or serious injury.
NOTICE
NOTICE is used to
latedtopersonalinjury.
NOTE indicates information that may help or guide
○
youintheopera
address practices not re-
NOTE
tion or service of the vehicle.
IMPORTANT NOTICE
THIS VEHICLE IS A COMP
ONLY AND WAS NOT MANUFACTURED
FOR, NOR SHOULD IT BE USED ON, PUBLIC STREETS, R OADS,
USE OF THIS VEHICLE SHOULD BE LIMITED
TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON
THIS VEHICLE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD RECREATIONAL RID ING.
READ OWNER ’S MANUA
ETITION MODEL
OR HIGHWAYS. THE
A CLOSED COURSE.
L.
WARNING
THIS VEHIC LE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD R
ING.
DISCLAIMER OF WARRANTY
This motorcycle is sold AS IS, with all faults,
obvious or conce
RANTIES expressed or implied.
Including warranties of MERCHANTABILITY or
FITNESS FOR PURPOSE.
The purchaser a
cerning quality, performance, cost of service
and/or necessary repairs.
aled and there are NO WAR-
ccepts all responsibilities con-
ECREATIONAL RID-
Motorcycle Noise Emi
Information
This motorcycle is designed for closed course
competition use only. It does not conform to
U.S. EPA motorcycle
Off-road motorcycling is a wonderful sport, and
we hope you will enjoy it to the fullest. However, if improperly conducted, this sport has
the potential to cause environmental problems
as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not
occur. TO PROTECT THE FUTURE OF YOUR
SPORT, MAKE SURE YOU USE YOUR MOTORCYCLE LEGALLY, SHOW CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS
OF OTHER PEOPLE.
ssion Control
noise standards.
NOTICE
WARNING
The engine exhaust from this product con-
tains chemicals known to the State of Cali-
fornia to cause cancer, birth defects or other
reproductive harm.
FOREWORD
Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of
Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight,
high-performance machine with superb handling and stability for racing and sporting use .
Your new KX is a highly tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This
manual is written to enable you to keep your KX properly tuned and adjusted.
Due to improvements in design and performance made during production, in some cases there may be minor
discrepancies between the actual vehicle and the illustrations and text in this manual.
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
© 2013 Kawasaki Heavy Industries, Ltd. Apr. 26, 2013. (1)
IMPORTANT NOTE TO PAR
This is a high perform
for beginners. Your youngster’s safety will depend on your commitment to always provide a safe riding
environment and a properly maintained vehicle. As with any moving vehicle there are possible safety
risks; be sure to hee
1. Always equip your child with suitable protective gear and riding apparel. Be sure he or she always
wears a helmet, eye protection, gloves, long pants, and a long-sleeved shirt while riding.
2. Never allow your child to carry a passenger. This motorcycle is designed for an OPERATOR ONLY.
3. This motorcycle is designed for off-road riding and should never be operated on public roads or
paved surfaces.
4. Always obey local off-road riding laws and regulations. Obtain permission to ride on private property.
5. You, the parent (and most likely “riding instructor/mechanic” as well), must be familiar with motorcycle
controls and maintenance requirements plus riding techniques. Read and understand the owner’s
manual provided with the motorcycle. Review all instructions and warnings with your child.
6. You must determine your child’s readiness to ride this off-road motorcycle. Your child should already
be familiar with motorcycle co ntro ls (location and function) and basic riding techniques. Your child
should also be physically large and strong enough to be able to straddle the motorcycle and hold it
up,plusbeabletopickitupifitisonitsside.
7. Before allowing your child to enter competition events, you must determine that he or she has the
necessary riding skills and physical/emotional maturity.
8. Your child’s safety depends in part on the good mechanical condition of the motorcycle. Be sure
to follow the maintenance and adjustment requirements contained in the Periodic Maintenance
Chart, Daily Pre-ride Inspection, and After-Race Check Points. Be sure your child understands the
importance of checking all items thoroughly before riding the motorcycle. Also, familiarity with the
motorcycle is important should a problem occur far from help.
9. Do not allow your child to ride unsupervised. He or she should always ride in the company of
an experienced adult.
10. Encourage your child not to ride beyond his or her skill level or faster than conditions safely allow.
Have them practice advanced riding maneuvers under controlled conditions.
11. Tell someone where you and your child are planning to ride and when you intend to return. Discuss
the ride with your child before you leave so he or she will know in advance what riding techniques
may be ne ce ssary to negotiate the terrain safely. If you are not familiar with the area, lead the
way and reduce your speed.
ance off-road motorcycle designed for experienced young riders. It is not suitable
d these precautions.
ENTS ABOUT SAFE RIDING
TABLE OF CONTENTS
SPECIFICATIONS.................. .......................... 9
GENERAL INFORMATION.............................. 15
Location of Labels ......................................... 15
Location of Parts ........................................... 19
Side Stand ..................................................... 22
Fuel ............................................................... 23
Fuel Requirement:..................... ................. 24
Kick Pedal ..................................................... 27
Starting the Engine ........................................ 27
Shifting Gears................................................ 29
Stopping the Motorcycle ................................ 30
Stopping the Engine ............... ....................... 31
Break-In........................................... .............. 32
Daily Pre-Ride Checks .................................. 34
After-Race Ch ecks .......................... .............. 36
MAINTENANCE AND A
Periodic Maintenance Chart .......................... 37
Transmission Oil .......................................... .. 41
Cooling System ............................................. 43
Spark Plug ..................................................... 48
Ignition Timing ............................................. .. 50
Air Cleaner ......................................... ........... 53
Throttle Cable ................................................ 58
Carburetor ....................................... .............. 60
Clutch ............................................................ 65
Piston ............................................................ 72
DJUSTMENT.............
37
Exhaust Syste m ............................................ 88
Drive Chain.................. .................................. 92
Handlebar ........ .................................... .......... 98
Brakes .............................................. ............. 101
Steering ................. .................................... .... 106
Front Suspension .......................................... 109
Rear Suspension (UNI
Wheels ............... .................................... ....... 126
Hoses Inspect ion ........................................... 129
Tightening Torques
Cleaning Your Motorcycle..... ......................... 135
Lubrication ....... .................................... .......... 137
TROUBLESHOOTING G
TUNING............................................ ................ 148
Carburetor ........................................ ............. 148
Suspension.................................................... 155
Gearing....................................... ................... 161
Special Care According to Track Conditions. 162
OPTIONAL PARTS .......................................... 163
PRE-RACE CHECKS AND AFTER-RACE
MAINTENANCE ............................................ 165
STORAGE................... .................................... . 167
Before Storage .............................................. 167
After Storage ................................................. 168
ENVIRONMENTA
WIRING DIAGRAM .......................................... 170
-TRAK
of Nuts and Bolts............
L PROTECTION..................
®
).....................
UIDE.........................
119
130
141
169
SPECIFICATIONS
DIMENSIONS
Overall Length:
KX85C 1 830 mm (72.05 in.)
KX100F
Overall Width 765 mm (30.12 in.)
Overall Height:
KX85C 1 100 mm (43.31 in.)
KX100F
Wheelbase:
KX85C 1 265 mm (49.80 in.)
KX100F
Road Clearance:
KX85C 290 mm (11.42 in.)
KX100F
Curb Mass:
KX85C 75kg(165lb)
KX100F
Fuel Tank Capacity 5.0 L (1.3 US gal)
1 920 mm (75.60 in.)
1 150 mm (45.28 in.)
1 310 mm (51.57 in.)
330mm(12.99in.)
77 kg (170 lb)
SPECIFICAT IONS 9
10 SPECIFICATIONS
ENGINE
Type 2-stroke, single-cy
Bore × Stroke:
KX85C 48.5 × 45.8 mm (1.91 ×
KX100F
Displacement:
KX85C 84 cm³ (5.1 cu in.)
KX100F
Compression Ratio:
Low Speed:
KX85C
KX100F 10.2:1
High Speed:
KX85C
KX100F 8.7:1
Port Timing:
Intake:
Open Full Open
Close
Scavenging:
Open:
KX85C 63.8° BBDC
KX100F
52.5 × 45.8 mm (2.07 ×
99 cm³ (6.04 cu in .)
10.9:1
9.0:1
–
62.8° BBDC
linder, piston reed valve, liquid-cooled
1.80 in.)
1.80 in.)
Close:
KX85C 63.8° ABDC
KX100F
Exhaust:
Open:
KX85C (Low speed) 79° BBDC
KX100F
Close:
KX85C (Low speed) 79° ABD
KX100F
Fuel System Carburetor, KEIHI
Starting System
Ignition System CDI
Ignition Timing:
KX85C 12° BTDC at 11 320 r/min (rpm)
KX100F
Lubrication System PETROL MIX (32:1)
Spark Plug NGK R6252K-105
Spark Plug Terminal Solid-post
TRANSMISSION
Transmission Type
Clutch Type
Driving System Chain Drive
62.8° A BDC
(Low speed) 81.7° B
(Low speed) 81.7° A
Primary Kick
12° BTDC at 12 640 r/min (rpm)
6-speed, Constant Mesh, Return Shift
Wet, Multi Disc
BDC, (High speed) 93.6° BBDC
C, (High speed) 93.6° ABDC
BDC, (High speed) 93.6° ABDC
NPWK28
SPECIFICAT IONS 11
, (High speed) 93.6° BBDC
12 SPECIFICATIONS
Gear Ratio:
1st
2nd
3rd
4th
5th
6th
Primary Reduction Ratio
Final Reduction Ra
KX85C 3.571 (50/14)
KX100F
Overall Drive Rat
KX85C 11.607 (Top gear)
KX100F
Transmission Oil
Grade API SG, SH, SJ, SL o
Viscosity
Amount
FRAME
Type Tubular, semi-double cradle
Steering Angle 45° to either side
Caster 29°
tio:
io:
:
2.538 (33/13)
1.875 (30/16)
1.500 (27/18)
1.250 (25/20)
1.090 (24/22)
0.956 (22/23)
3.400 (68/20)
3.923 (51/13)
12.758 (Top gear)
SAE 10W-40
0.7 L (0.74 US qt)
r SM with JASO MA, MA1 or MA2
Trail:
KX85C 97 mm (3.82 in.)
KX100F
108 mm (4.25 in.)
Tire Size/Type:
Front:
KX85C 70/100-17 40M/DUNLOP MX51F
KX100F
70/100-19 42M/DUNLOP MX51F
Rear:
KX85C 90/100-14 49M/DUNLOP MX51
KX100F
90/100-16 52M/DUNLOP MX51
Rim Size:
Front:
KX85C
17 × 1.40
KX100F 19 × 1.40
Rear:
KX85C
14 × 1.60
KX100F 16 × 1.85
Suspension:
Front
Telescopic fork (u
Rear Uni-trak
®
swingarm
pside-down)
Front Suspension Travel 275 mm (10.83 in.)
Rear Wheel Travel
275mm(10.83in.)
SPECIFICATIONS 13
14 SPECIFICATIONS
Front Fork Oil:
Type
Amount
BRAKES
Type:
Front
Rear
Brake Fluid G rade:
Front
Rear
Specifications are subject to change without notice.
Kawasaki Fork Oil KHL15-10
295 ∼ 325 mL (9.97 ∼ 11.0 US oz.)
Single disc
Single disc
DOT3 or DOT4
DOT4
GENERAL INFORMATION
Location of Labels
All warning labels which are on your vehicle are
repeated here. Read lab
derstand them thoroughly. They contain information
which is important for your safety and the safety of
anyone else who may ope
fore, it is very important that all warning labels be on
your vehicle in the locations shown. If any label is
missing, damaged, or
your Kawasaki dealer and install it in the correct position.
The sample warning labels in this section have
○
part numbers to help
the correct replacement.
els on your vehicle and un-
rate your vehicle. There-
worn, get a replacement from
NOTE
you and your dealer obtain
GENERAL INFORMATION 15
j
1. Brake Fluid (Front)
16 GENERAL INFORMATION
2. Radiator Cap Danger
3. Rear Shock Absorber Warning
4. Gasoline-Engine Oil Mixing Ratio
5. Disclaimer of Warranty
6. Noise Emission Control Information
7. Important Information
1)
3)
GENERAL INFORMATION 17
j
2)
4)
18 GENERAL INFORMATION
5)
6)
7)
Location of Parts
GENERAL INFORMATION 19
j
1. Clutch Lever
2. Front Brake Fluid Reservoir
3. Front Brake Lever
4. Engine Stop Button
5. Fuel Tank Cap
6. Throttle Grip
20 GENERAL INFORMATION
1. Front For
2. Radiator
3. Fuel Tank
4. Carbure
5. Seat
6. Air Cleaner Element
7. Muffle
8. Front Brake Disc
k
tor
r
9. Front Bra
10. Expansion Chamber
11. Shift Pedal
12. Rear Sho
13. Swingarm
14. Chain Guide
15. Drive C
ke Caliper
ck Absorber
hain
GENERAL INFORMATION 21
j
1. Rear Shoc
2. Rear Brake Fluid Reservoir
3. Fuel Tap
4. Rear Bra
5. Rear Brake Caliper
k Absorber Gas Reservoir
ke Disc
6. Transmis
7. Rear Brake Pedal
8. Kick Pedal
9. Water Pu
sion Oil Level Inspection Window
mp Cover
22 GENERAL INFORMATION
Side Stand
Support the motorcyc
stand. Install the upper end of the side stand into
the hole at the rear of the left footpeg.
A. Side Stand
B. Hole
le with the provided side
WARNING
Ridingwiththesidestandcancauseacrash
resulting in injury. Do not start the engine or
attempt to ride
stand is installed.
the motorcycle when the side
NOTE
Support the motorcycle with a suitable stand to
○
perform maintenance or adjustment procedures.
Fuel
GENERAL INFORMATION 23
Avoid filling the tan
k in the rain or where heavy dust
is blowing so that the fuel does not get contaminated.
j
The Kawasaki KX is equ
ipped with a 2-stroke en-
gine that requires a gasoline-oil mix ture.
Fuel Tank Capacity
5.0 L (1.3 US gal)
To open the fuel tank cap, pull out the breather
hose from the hole in the steering shaft, and turn the
tank cap counterclockwise.
uel Tank Cap
A. F
B. Breather Hose
A. Fuel Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
24 GENERAL INFORMATION
WARNING
Gasoline i s extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Always stop
the engine and do not smoke. Make sure
theareaiswellventilatedandfreefromany
source of flame or sparks; this includes any
appliance with a pilot light. Never fill the tank
completely to the top. As the fuel expands
in a warm tank, it may overflow through the
vents in the tank cap. After refueling, make
sure the fuel tank cap is closed securely. If
gasoline is spilled on the fuel tank, wipe it off
immediately.
Fuel Requirement:
Fuel Type
Use clean, fresh unleaded gasoline with a min imum Antiknock I
posted on service station pumps in the U. S.A. The
octane rating of a gasoline is a measure of its resistance to de
Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) as
shown in t he t
Octane Rating Method
Antiknock Index
ndex of 90. The Antiknock Index is
tonation or “knocking”. The Antiknock
able below.
Minimum
Rating
(RON + MON)
2
90
NOTICE
If engine “knocking” or “pinging” occurs,
use a different brand of gasoline of a higher
octane rating.
If this condition is allowed to continue it can
lead to severe engine damage.
Gasoline quality is
quality or not meeting standard industry
specifications may result in unsatisfactory
performance. Oper
from the use of poor quality or nonrecommended fuel may not be covered under your
warranty.
Fuels Containing Oxygenates
Gasoline frequently contains oxygenates (alcohols and ethers) especially in areas of the U.S.
and the C anada which are required to sell such
reformulated fuels as part of a strategy to reduce
exhaust emissions.
The types and volume of fuel oxygenates approved for use in unleaded gasoline by the U.S.
Environmental Protection Agency include a broad
range of alcohols and ethers, but only two components have seen any significant level of commercial
use.
Gasoline/Alcohol Blend s - Gasoline containing up
to 10% ethanol (alcohol produced from agricultural
products such as corn), also known as “gasohol” is
approved for use.
important. Fuels of low
ating problems that result
NOTICE
Avoid using blends of unleaded gasoline and
methanol (wood alcohol) whenever possible,
and never use “gasoh
than 5% methanol. Fuel system damage and
performance problems m ay result.
Gasoline/Ether Blends - The most common ether
is methyl tertiary butyl ether (MTBE). You may use
gasoline contain
Other oxygenates
○
gasoline include TAME (up to 16.7%) and ETBE
(up to 17.2%). Fuel containing these oxygenates
canalsobeusedi
ingupto15%MTBE.
ol” containing more
NOTE
approved for use in unleaded
n your Kawasaki.
GENERAL INFORMATION 25
NOTICE
Never use gasoline with an octane rating lower than the minimum specified by
Kawasaki.
Never use “gasohol” with more than 10%
ethanol, or more than 5% methanol. Gasoline containing met
blended with cosolvents and corrosion
inhibitors.
Certain ingredien
paint fading or damage. Be extra careful
not to spill gasoline or gasoline oxygenate
blends during ref
When not operating your Kawasaki for 30
to 60 days, mix a fuel stabilizer (such as
STA-BIL) with th
Fuel stabilizer additives inhibit oxidation of
the fuel which minimizes gummy deposits.
Never store this
the fuel system. Before storage it is recommended that you drain all fuel from the fuel
system. See the
ual.
hanol must also be
ts of gasoline may cause
ueling.
e gasoline in the fuel tank.
product with “gasohol” in
Storage section in this man-
j
2-Stroke Oil
Oil must be mixed with the gasoline to lubricate
the piston, cylinder, crankshaft bearings, and connecting rod bearings.
26 GENERAL INFORMATION
Recommended Oil
Kawasaki Performance 2-Stroke Racing Oil*
or equivalent 2-stroke engine lubricant
*Kawas
been specifically engineered for your vehicle. Consistent use of these products meets or exceeds service r
your Kawasaki.
Gasoline-Engine Oil Mixing Ratio
A 32-to-1 mixture is about 31 mL of oil per liter of
gasoline or 4 fluid ounces of oil per gallon of gasoline.
aki Performance Oils and Lubricants have
equirements and can help to extend the life of
32:1 (Gasoline:Engine Oil)
NOTICE
Do not use vegetable and mineral oils.
Too much oil will cause excessive smoking
and spark plug fouling. Too little oil will
cause engine damage or premature wear.
To prepare the gasoline-oil mixture, pour the oil
and half of the gasoline into a container first and stir
thoroughly. Then, add the rest of the gasoline and
stir the mixture well.
NOTE
At low temperature, oil will not easily mix with
○
gasoline. Take time to ensure a well-blended
mixture.
The lubricative quality of the gasoline-oil mixture
○
deteriorates rapidly; therefore, prepare a fresh
mixture for each day of operation.
GENERAL INFORMATION 27
j
Kick Pedal
This motorcycle is eq
starting system. When the clutch lever is pulled, the
motorcycle can be started with the transmission in
any gear.
A. Kick Pedal
uippedwithaprimarykick
Starting the Engine
Turn the fuel tap leve
•
A. Fuel Tap
B. ON position
Shift the transmission into neutral.
•
r to the “ON” position.
WARNING
Ridingwiththesidestandcancauseacrash
resulting in injury. Do not start the engine or
attempt to ride the motorcycle when the side
stand is installed.
28 GENERAL INFORMATION
NOTICE
This motorcycle is designed for competition
use only. Therefore, the radiator does not
incorporate a coola
ing fan. Prolonged idling of the engine with
no airflow through the radiator can cause
coolant loss and en
ing in possible engine damage. Any riding
conditions that increase engine temperature
will further redu
loss occurs. These conditions include high
ambient temperature, sandy or muddy terrain, or other co
loads at low speeds. Furthermore, warming
the engine up excessively before operation,
or leaving idli
ature after operation results in the engine
overheating, too.
When engine is cold -
Pull up the ch
•
ng with the hot engine temper-
oke knob.
nt reserve tank or cool-
gine overheating result-
ce idling time before coolant
nditions causing high engine
A. Choke Knob
Kick the engine over, leaving the throttle closed.
•
Even after the engine has started, do not push
•
back immediat
is thoroughly warmed up.
ely the choke knob until the engine
NOTE
If the engine is flooded, kick it over with the throttle
○
fully open until it starts.
When the clut
○
be started with the transmission in any gear.
ch lever is pulled, the m otorcy cle can
When engine is already warm -
When the engine is already warm or on hot days,
•
open the throttle part way instead of using the
choke knob.
NOTE
If the engine fails starting, open the throttle fully
○
and depress the kick pedal slowly about 4
times to c lear too rich fuel mixtures in the engine.
Then, kick the engine over, leaving the throttle
closed.
GENERAL INFORMATION 29
j
Shifting Gears
∼
5
This motorcycle is eq
shift” transmission. The neutral is located halfway
between 1st and 2nd gear. “Return shift” means
that when shifting up
engaged before the next higher o r lower gear may
be selected.
To engage 1st gear f
•
in the clutch lever and push down on the shift
pedal, gently release the clutch lever, then release
the shift pedal.
To shift up to the next gear, pull in the clutch lever,
•
lift the shift pedal with your toes, gently release the
clutch lever, an
To shift down to the next gear, pull in the clutch
•
lever, push the shift pedal down as far as it will go,
gently release t
shift pedal.
uipped with a 6-speed “return
or down, each gear must be
rom the neutral position, pull
d then release the shift pedal.
he clutch le ver, then release the
NOTICE
When changing gears, press firmly on the
shift pedal to ensure proper shifting. Care-
less, incomplete shifting can cause the
transmission to jump out of gear and lead to
engine damage.
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